Method for producing crimped fiber



May 9, 1961 F. c. SKALKO METHOD FOR PRODUCING CRIMPED FIBER 5Sheets-Sheet 1 Filed July 19. 1956 INVENTOR: Fmzxmzs L KALKD. BY

ATTORNEYS.

May 9, 1961 F. c. SKALKO 2,983,026

METHOD F OR PRODUCING CRIMPED FIBER FiledJuly 19. 1956 5 Sheets-Sheet 2INVENTOR FRANCIS L. EKALKLI 4 ATTORNEYS F. c. SKALKO 2,983,026

5 Sheets-Sheet 3 May 9, 1961 METHOD FOR PRODUCING CRIMPED FIBER FiledJuly 19. 1956 I I I I I I I I I I I I I I I I I I IIIIII |"T PT III May9, 1961 F. c. SKALKO 2,983,026

METHOD FOR PRODUCING CRIMPED FIBER Filed July 19. 1956 5 Sheets-Sheet 4INVENTORI FRANCIS L7. SKALKU.

BY MA ORNEYS.

May 9, 1961 F. c. SKALKO METHOD FOR PRODUCING CRIMPED FIBER Filed July19. 1956 5 Sheets-Sheet 5 INVENTOR:

55mm. Tq'oRNEYs.

Emma's E United States Patent METHOD FOR PRODUCING CRIMPED FIBER FrancisC. Skalko, Pawtucket, R.I., assignor to Owens- Corning FlberglasCorporation, a corporation of Delaware Filed July 19, 1956, Ser. No.598,796

2 Claims. (CI. 28-72) This invention relates to a method for producingcrimped, corrugated, wavy or curly fibers of glass or otherheat-softenable fiber-forming material and more especially to a methodadapted and arranged to impart a crimp or curly configuration to alinear bundle of fibers or filaments.

Methods have been developed for imparting a crimped or curlyconfiguration to filaments or fibers wherein the crimping or curlingoperation is performed by directing linear bodies or streams of glassfrom a stream feeder between intermeshing toothed elements from a feederwhile the bodies or streams are in a semi-solid or plastic condition.Through such method the successive crimps or bends formed in thefilaments or fibers become fixed upon chilling. Apparently, due to thefixation of all of the crimps or bends in the fiber, the carding orpicking of crimped or curly fibers formed by this method is not entirelysatisfactory as the fibers tend to load up or cling to the carding orpicking rolls resulting in considerable waste of material and threads oryarns formed from the carded fibers are of inferior quality.

The present invention embraces a method wherein fiber in the form oflinear bundles of filaments or fibers, yarns, rovings, strands orthreads are engaged by crimping elements under temperature conditionswhich will result in alternate crimps or bends being permanently fixedin the fiber.

Another object of the invention is to provide a method wherein linearbundles of preformed fibers of glass or other mineral material aresubjected to diiferential temperatures for producing a crimped or curlyconfiguration therein.

Another object of the invention is the provision of a method of formingcrimps or curls in glass fibers or the like wherein the shape, sharpnessor acuteness of the crimp or bend configuration may be varied andcontrolled.

Another object of the invention is the provision of a method whereinspaced crimps of different magnitude may be alternately impressed alongthe length of a linear bundle of fibers or filaments on opposite sidesof the bundle forming a continuous pattern or shape resembling a runningW in a planar direction.

Another object of the invention relates to method of crimping a linearbundle of glass fibers wherein successive groups of crimpedconfigurations may be imparted to a strand or linear bundle of fibersalternately on opposite sides of the strand or bundle, such groups ofcrimped configurations being formed by heating and cooling successivezones of the bundle of fibers to provide a balanced crimped or curlyfiber.

Another object of the invention is the provision of apparatus forforming crimped or curly fibers wherein the fiber engaging elements orcomponents are adjustable in order to control the magnitude, shape andcharacter of the crimped or curled configurations imparted to thefibers.

Another object is the provision of an apparatus for engaging successivezones of a bundle of glass fibers 2,983,026 Patented May 9, 1961 withelements which are at differential temperatures whereby successivegroups of crimped or curly configurations are impressed in oppositesides of the bundle of fibers so that the ultimate crimped or curledbundle of fibers is provided with successive helical curvatures ingenerally oppositedirections.

Another object of the invention is the provision of a method ofdeforming a strand or linear bundle of fibers providing a threedimensional configuration in a linear pattern wherein comparativelysharp crimps are fixed in the strand or bundle connected by gradualcurved portions.

Another object of the invention is the provision of a method of andapparatus for forming curled or crimped fiber wherein the fiber iscontinuously fed into contact with surfaces shaped to impart a sinuousconfiguration to the fiber, the surfaces being of different temperatureswhereby a crimp or curl is imparted to one side of the fiber.

Another object is the provision of a method of crimping or curling fiberor bundles of fiber wherein the degree or magnitude'of crimp deformationmay be varied and controlled to secure various forms of deformation ofthe fiber.

Another object of the invention is the provision of apparatus fordeforming fiber wherein the fiber is delivered into heat transferringrelation with surface zones at differential temperatures for imparting acrimped or curled shape to the fiber and wherein the temperatures of theheat transferring zones and the character of the path of traverse of thefiber through said zones may be controlled, changed or modified todetermine the resultant shape, pattern or configuration imparted to thefiber.

Further objects and advantages are within the scope of this inventionsuch as relate to the arrangement, operation and function of the relatedelements of the structure, to various details of construction and tocombina: tions of parts, elements per se, and to economics of manu'-facture and numerous other features as will be apparent from aconsideration of the specification and drawing of a form of theinvention, which may be preferred, in which:

Fig. l is a diagrammatic side elevational view of a form of apparatusfor carrying out the method of the invention of deforming fiber orbundles of fiber;

Figure 2 is a detail sectional view illustrating a means for feeding orconveying fiber;-

Figure 3 illustrates a form of crimp or curl imparted to fiber utilizingthe method and apparatus of the in- Figure 8 is a side elevationalviewof a portion of thearrangement shown in Figure 7, certain partsbeing shown in section;

Figure 9 is an in Figure 7 with certain elements removed and othersbroken away for purposes of illustration; Figure 10 is a fragmentarydetail sectional view taken substantially on the line 10--10 of Figure9; Figure 11 is an isometric view of a portion of the structure shown inFigure 10;

end view of the apparatus illustrated Figure 12 is an isometric view ofone of the fiber engaging and deforming elements;

Figure 13 is an isometric view of one of the fiber engaging projectionsor blades; I

Figure 14 illustrates a means for securing the blades in position on acircular cylindrical roll,-

Figure 15 is a fragmentary sectional view illustrating assembly of theelements or components shown in Figures 12 through 14;

Figure 16 is a semidiagrammatic section view illustrating a modifiedform of apparatus of the invention, and

Figure 17 is an isometric view illustrating one of the fiber engagingelements shown in Figure 16.

The method and apparatus of the invention are particularly adaptable foruse in imparting or establishing crimped or curled configurations infibers of mineral material, such as glass, and the invention in itsbroader aspect is applicable in the formation of crimps, curls, or thelike in fibers formed of other heatsoftenable materials such as fusiblerock slag or any material which may be deformed at elevated temperaturesand in which the deformation is rendered substantially permanent atnormal temperatures. The method and apparatus of the invention areusable for crimping or curling fiber strands in which the fiber may bein the form of continuous filaments, slivers, 'yarns both twisted andplied, threads, rovings or bundles of fibers, and the use herein of theterms fiber and bundles of fiber are intended to include the types ofmaterials mentioned above.

The principles of the invention involve the steps of delivering bundlesof fiber into engagement with elements or surfaces shaped to impart acrimped or curled pattern or configuration to the fiber or bundles offiber wherein opposite sides or zones of bundles of fiber are subjectedto differential temperatures, the elevated temperature of one surface orzone being sulficiently high to render the adjacent zone of the bundlesof fiber plastic to the extent that the bundles of fiber are deformed bythe surfaces to predetermined configuration, such as a crimped or curledshape, and which becomes permanent or fixed upon the fiber moving awayfrom the region of differential temperature.

It has been found that upon engagement of the opposed regions oropposite sides of bundles of fiber with surfaces at differentialtemperatures, crimps or curls are established wherein the connectingregions between fixed crimps or curls are generally curved andyieldable, facilitating the further processing of the crimped or curledfibers through carding and other textile operations or after treatments,providing an improved product. Crimped or curled fibers made inaccordance with the method of the invention facilitate better spinningwith a minimum of fiber breakage. Such crimped or curled fibers improvebulking and provide low density and high resiliency characteristicswhere the fibers are utilized for wadding, batting, pillow stufling andkindred uses.

Referring to the drawings in detail and initially to Figure 1 there isillustrated in diagrammatic form the steps in the method of deformingfibers or bundles of fiber into crimped or curled configuration. Thebundles of fiber P which may be in the form of rovings, slivers, yarnsor the like are withdrawn from packages G mounted upon spindlessupported upon a creel structure 11. The bundles of fiber F are passedover a spacing bar 14 provided with projections for spacing theindividual bundles of fiber and are delivered between fiber deforming,crimping or curling surfaces and 15.

As shown diagrammatically in Figure l, the fiber engaging surfaces 15and 15' are inclusive of spaced projections, overlapping elements, finsor teeth 17 resembling gears in loosely meshing relation.

As hereinafter described the crimping or curling structures includemeans for establishing differential temperatures at opposite sides orregions of the bundles of fiber whereby one region of the fiber iselevated in temperature by heat transfer to a softened or plasticcondition such that the deformation formed therein by engagement withthe crimping surfaces establishes crimps or curls in the fibers whichare substantially permanent.

Each of the continuous bundles of crimped or curled fiber, upondisengagement from the crimping surfaces enters a conveying tube 20,there being one tube for each bundle of fiber illustrated in Figure l.Mounted upon or associated with each of the fiber enclosing tubes 20 isa fiber feeding or advancing means 22, one of the fiber conveying orfeeding units 22 being shown in section in Figure 2.

The fiber feeding or withdrawing means 22 may be of the air lance typewherein the movement or inspiration of air through a passage effectivelyconveys the bundle of fiber through the passage and away from thecrimping or curling surfaces. The fiber advancing devices 22 are mountedupon pipes or tubes 24 which are connected with a manifold or supplypipe 26 connected with a source of compressed air for delivering airunder pressure to the fiber feeding devices.

The crimped or curled fibers F are delivered or collected in containersor receptacles 28 in the manner illustrated in Figure 1, there being anindividual collector or container for each of the crimped bundles offiber. If desired more than one bundle of crimped fiber may be withdrawnby each of the feeding or withdrawing devices 22 and several bundles offiber fed into a single collector or collecting zone.

Figure 2 illustrates a form of fiber feeding or withdrawing device 22.In the form illustrated, the feeding device includes a generallycircular housing 32 having an inner circular wall 34 defining a passage35 to accommodate the crimped fiber, the inner and outer walls of thehousing 32 forming an annular chamber 36. A circular plate 38 secured tothe housing 32 forms a wall of the chamber 36. The plate 38 is formedwith an annular comically-shaped wall 40, the exterior surface 41thereof and a conically-shaped surface 42 providing an annular passage44. A fiber guiding tube 20 is connected to the plate 38 to direct thebundle of crimped fiber to the feeding or withdrawing device. The tube24 conveys air or gas under pressure to the annular chamber 36, the airor gas being projected through the frusto-conically shaped passage 44and into engagement with the bundle of crimped fiber F drawing thecrimped fiber through the tube 20 for delivery into a fiber collectingcontainer 28 or other fiber collecting region.

While four rovings, strands or bundles of fiber F are illustrated inFigure 1 being processed simultaneously through the crimping apparatus,it is to be understood that any number of rovings, strands, yarns, orbundles of fiber, may be processed through the crimping device, limitedonly by the amount that may be accommodated within the length of thecrimping rolls or surfaces. As a typical example, the apparatus mayaccommodate a large number of rovings where each roving is formed withapproximately sixty strands and each strand formed of two hundred ormore continuous filaments or fibers.

Figures 5 through 11 illustrate in detail a form of apparatus especiallyadapted for imparting crimps or curls to a plurality of rovings orbundles of fiber delivered to the crimping or curling surfaces in themanner illustrated in Figure 1. The apparatus includes a frame structure50 which includes a base or table portion 51, supporting legs 52 andbracing members 53.

Fixedly mounted on plate 51 is a member 57 which supports longitudinallyspaced bearing blocks or supports 60, these bearing blocks being securedin place by means of bolts 61. Also mounted upon the supporting member51 is a plate 66 which extends longitudinally of the frame 50. The plate66 supports hearing or journal blocks 68; which aresecured to. the plate66 by means of bolts .70.

The plate 66 is adapted for transverse sliding movement relative to thesupporting member 51. The end zones of plate 66 are notched or recessedas at 72 to accom= modate securing bars or members 74 which are mountedupon transversely extending ways or blocks 76, the latter forming guidesto facilitate transverse movementor adjustment of the plate or member66.

As particularly shown in Figure 9, the plates 74, 76 and the tableportion 51 are bored to accommodate headed clamping bolts 78, the heads79 of which engage the upper surface of the plates 74. The threadedportions of the bolts 78 extending below the plate 51 extend throughspacers 80 are provided with knurled clamping nuts or members 82 whichare manually movable to lock and unlock the-clamping plates 74 inengagement with the end zones of the plate 66 carrying the journalblocks 68. v

Mechanism or means is provided for adjusting the position of plate 66relative to the bearing blocks 60 in order to vary or change the extentof enmeshment or overlap of the. crimping projections 17. .The plate 66is formed with threaded bores to accommodate threaded members 84 whichare journaled for rotation in boresformed in plates or members 86secured to housings 87 carried by the table 51. Secured on an endportion of each member 84 and contained within a housing 87 is a wormwheel 88, each worm wheel being enmeshed with a worm 90', the wormsbeing secured upon and adapted to be rotated by a shaft92= journaled inbearing blocks 93.

A manipulating or hand wheel 95 is secured to each end of the shaft 92.By rotating either of the hand wheels 95, the worms 90 simultaneouslyrotate the worm wheels 88 and the threaded members 84 to move or adjustthe plate 66 and bearing members 68 transversely yet maintaining thejuxtaposed zones of the fiber curling or crimping surfaces 15 inparallel relation.

The fiber engaging, crimping or curling projections 17 forming thesurfaces or zones 15, are carried or mounted upon circular cylindricalrolls or drums 100 and 100, each drum or roll being formed withcircumferentially spaced slots 102 shown in Figure 12.

Each slot is adapted to receive a blade, fin or longitudinally extendingprojection 17, one of which is shown in Figure 13. The projections onthe drums provide, in etfect, two groups of circumferentially spacedteeth resembling spur gears which are in enmeshing' or overlappingrelation as shown in Figures 1 and 9 and are adapted to engage fiber orbundles of fiber to crimp or curl the same in a manner hereinafterexplained. Each of the projections or blades 17 is formed with anextension or tongue 106 at each end to accommodate a band or annulus 108surrounding the tongues 106 as shown in Figure 15 to secure the bladesor projections 17 in the slots 102. 7

Each of the cylindrical members or drums 100 and 100' is supported atits ends upon disk-like members 110 secured to bushings or sleeves 112as shown in Figure 7. Circular plates 114 of refractory or othermaterial having high heat resistance characteristics are supportedinteriorly of the drum and carried by the members 110. The drums 100 and100 are rotated with the members 110 through the medium of drive pins115 which extend into the end zones or regions of the slots 102.

The sleeves 112 are journaled in bearings 117 sur' rounded by sleeves118 carried in bearing supports or blocks 60 and 68 disposed adjacentthe ends of the drums 100 and 100. The bearing blocks are formed withannular chambers 120 surrounding the sleeves 112 to accommodate acirculating cooling fluid or medium con veyed into and away from thechambers 120 by inlet and outlet pipes 122 and 123.

Means for driving the rolls or drums includes a gear 125 secured to oneend of one of the sleeves 1.12 supporting the roll and a gear 128secured to the end of one of the sleeves supporting the roll 100' asshown in Figures 7 and 9. Disposed adjacent the gears and Figures 9 to11.

of screws 133.

The member 13 2 forms a journal or hearing for rotatably supporting ashaft 134. As shown in Figures 10 and 11, one end of the shaft 134 isformed with a tenon portion 136 which receives a driving gear 138 heldto the tenon portion by means of a pin 139 whereby the gear 138 isrotated with the shaft 134. The tenon portion 136 of shaft 134 isjournaled in a suitable bearing 140 carried by the triangularly shapedmember 130 as shown in Figures 10 and 11.

The outer extremity of the shaft 134 is equipped with a pulley 143 shownin Figures 5, 6 and 7. A belt 145 connects pulley 143- with a drivingpulley 147 mounted upon a shaft 148 adapted to be driven throughsuitable reduction'gearing contained in a housing 152 by an electricallyenergizable motor 150 or other suitable source of power.

The rate of rotation of the fiber engaging and crimping rolls 100 and100 may be regulated by the speed reducing means contained within thehousing 152 which may be controlled by a control member 154.

The triangularly shaped member 130' is provided with a threaded borearranged to receive a threaded portion 158 formed on a stub shaft 160.Journaled upon the shaft'or pin 160 is a gear 162 which is in constantmesh with gear 138, as shown in Figures 9 and 10, and is arranged to bedriven by gear 138. The gear 138 is meshed with gear 125 and gear 162 ismeshed with gear 128 whereby gears 125 and 128 are simultaneously drivenin opposite directions at the same speed by gears 138 and 162.

The pair of bearing supports 68 for the drum or roll 100' are movabletransversely so as to move the fiber engaging fins or teeth 17 thereoftoward or away from the fins or teeth on the roll 100 to vary the size,character and shape of the crimps or curls imparted to the fiber orbundles of fiber. In order to maintain a drive enmeshment of the gear162 with gear 128 when the latter is moved relative to the gear 162,means is provided for moving the gear 162 into proper mesh with theteeth of gear 128.

As shown in Figures 9, 10 and 11 the triangularly shaped member 130 isprovided with a cylindrically shaped projecting portion 165 which isbored to accommodate a cylindrically shaped head or member 166 which isdisposed for limited oscillation in a bore formed in the projection 165.A connecting link or shaft 167' is threaded into a transverse boreformed in the head or member 166 and extends transversely through a slot168 in a wall of member 165 as shown in Figures 9 and 10. I

As the triangularly shaped member 130 is mounted upon the tenon portion136 of the shaft 134 for pivotal movement about the axis of the shaft,transverse move= ment of rod 167 swings the triangular member 130 and agear 162 about the axis of the shaft 134 to effect a proper meshingrelation of gear 162 with gear 128.

Secured to the plate 51 by means of screws 170 is an,

upwardly extending member 172. The member 172 is bored to receive athreaded portion 168 of the shaft 167 as shown in Figure 9. Threadedupon the portion 168 and disposed on opposite sides of the support 172is a manipulating member 174 and knurled lock nut 175.

By manipulation of member 174 and lock nut 175, the.

shaft 167 may be adjusted lengthwise, swinging the triangularly shapedmember 130 about the axis of the shaft 134 to move the gear 162 intoproper meshing relation with the gear 128 of the transversely adjustableroll Heating or temperature controlling means is provided for each ofthe drums or members 100 and 100 for establishing predeterminedtemperatures of the fiber engaging and crimping elements or projections17 carried by the drums. With particular reference to Figures through 9the drums are respectively provided with heating or temperaturecontrolling elements 180 and 181.

The heating units or elements 180 and 181 may be of any desired typepreferably adapted to be electrically energized to control thetemperature within the drums and thereby control the temperature of thefiber engaging projections 17 on each of the drums. In the embodimentillustrated, the heating elements or units 180 and 181 are of theresistance rod type comprising a composition of carbon and binder, suchas silicon carbide.

As will be apparent in Figure 7, the sleeves 112 carrying the drums 100and 100 are of hollow configuration to accommodate the heating units orelements 180 and 181. The interior walls of the sleeves 112 are spacedsufficiently from the heating elements to prevent contact therewith.

Secured to each of the bearing supports 60 and 68 is a bracket 184, heldto the bearing supports by means of screws 185. Each of the bracket 184is provided with a sleeve or bushing 186 formed of high temperatureresistant insulating material which provides support for the resistanceheating elements 180 and 181. Secured to the end zones of each of theheating elements is a bus bar or connector 188 which is joined with acurrent conductor 190 by means of a bolt 192 insulatingly supported uponeach of the brackets 184, as particularly shown in Figures 7 and 8. Theconductors 190 are connected with a suitable source of electrical energyfor supplying current to the resistance elements 180 and 181 to provideheat interiorly of the drums 100.

The drums or members 100 and 100' equipped with fiber engaging fins orprojections are substantially enclosed by suitable heat resistantjackets or enclosures 195 and 196. As particularly shown in Figure 9each of the jackets or enclosures includes a metal shell comprisinginner and outer walls 198 and 199, the space between the wallscontaining a heat resistant material 200 formed of glass fibers or thelike. Each of the jackets or enclosures 195 and 196 may be hinged as at202 to facilitate swinging the jackets or enclosures away from the drumsfor purposes of inspection.

As shown in Figure 9, the jackets or enclosure are spaced to provide apassage 204 to accommodate the fiber or bundles of fiber moving intoengagement with the crimping elements of the drums. The outer metal wall199 of each insulating packet is covered with an additional layer 206 offlexible insulating material. Each of the jackets or enclosures may beprovided with a handle 208 to facilitate manipulation of the jackets.

As particularly shown in Figure 9, a support or fitting 210 is mountedupon each of the metal walls 199 and encloses a thermosensitive elementor couple 212, each being connected with a suitable temperatureindicating instrument for the purpose of accurately determining thetemperature adjacent each of the fiber crimping elements.

In the operation of the arrangement hereinbefore described it isdeirable to regulate the temperatures of each of the fiber engaging drumor elements whereby the temperature of one of the fiber engaging drumsis sufiiciently elevated to effect a softening of the fiber or bundlesof fiber engaging the crimp forming projections. The temperature of theother fiber engaging drum is preferably below the softening point of theglass or other mineral material of the fiber or bundles of fiber to becrimped or curled.

It has been found that by heating one of the fiber engaging elements toa temperature of about 1200 F. and maintaining the temperature of theother fiber engaging element at about 600 F. a sufiicient temperature 8differential is established to attain a desired crimp or curlconfiguration in the fiber or bundles of fiber.

The fiber engaging roll or drum of the higher temperature is hereinreferred to as the hot roll and the fiber engaging drum or roll of lowertemperature is herein referred to as the cold roll. It is to beunderstood that the temperatures indicated herein for the fiber engagingrolls are exemplary and have been found to produce a desired crimp orcurl to the fiber, but the rolls may be maintained at other temperaturesdepending upon the characteristics desired in the crimped or curledproduct.

Figure 3 is exemplary of a crimp or curl fixation imparted to the fiberor bundles of fiber formed by engagement with the projections 17 whereinone element or hot roll is at 1200 F. and the other at approximately at600 F. As shown in Figure 3, the apex- 215 of each crimp or curl is ofrather sharp definition and this configuration is formed by engagementof the fiber with the projections on the hot roll The sharpness of thebend at the apex 215 is caused by a partial softening of the fiberengaging the hot projections whereby the glass or mineral material ofthe fiber is endowed with a substantially permanent or fixed crimp orbend 215, the crimps, curls or bends being spaced along the fiber bysuccessive engagement of the heated fins or projections with the fiber.

The logs 217 of each crimp or curl 215 are joined by arcs or curvesindicated at 219 which are not of sharp bend as the apices 215 for thereason that the projections or fins of the cold roll engage the portions219 of the crimped or curled fiber. The fins or projections on the coldroll 100 are below a temperature which will soften the glass or mineralmaterial of the fiber and hence the curved portions 219 are formed byreason of the permanent or fixed bends or crimps impressed in the fiberat the zones 215.

By reason of the fixation of the bends or apices 215 at one side of thecrimped or curled fiber, the stress of fixation tends to form the fiberin an are as shown in Figure 3, which in continuity generally become ahelix in configuration. It has been found that the direction of thegeneral helical deformation is toward the hot roll.

By providing the fixation zones of the crimp at only one side of alinear bundle of fiber, the crimped or curled fiber, when chopped andtreated for further processing, gives improved results in carding withless waste and may be more readily spun than other types of crimped orcurled fiber. The crimps 215 and curved zones 219, for the reasons abovementioned, are of two magnitudes, and are alternately disposed along thelength of the strand or bundle of fiber and on opposite sides thereof asshown in Figure 3.

One factor present which controls the tightness of individual ordiscrete crimps or curls is the degree of bend or crimp imparted to thefiber or bundles of fiber during setting or fixation of the portionbeing deformed by heating. This characteristic is dependent upon suchfactors as the duration of contact with the hot fins or projections, thedegree of interenmeshment or overlap of the fins or projections on therolls, the tension of the fiber or bundles of fiber being crimped, andthe shape of the fins or projections. The tension on the fiber orbundles of fiber in a measure determines the rapidity and effectivenessof heat transfer from the hot fins or projections to the fiber as wellas the sharpness or acuteness of conformation of the fiber to the finshape.

The operation of the apparatus in carrying out the method of theinvention is as follows: The resistance heating units 180 and 181 areenergized with a suificient amount of current to establish the desiredtemperature differential between the drums 100 and 100' to heat theprojections on one drum to a temperature sufiicient to soften the fibersor filaments and to maintain the teeth or projections on the other drumat a lower temperature. A hereinbefore mentioned the temperature of thehot 9 crimping projections may be at approximately 1200' F. and theprojections of the so-called cold roll at a temperature to 600 F. atemperature below the softening temperature range of the material to becrimped or curled.

The locking bolts or rods 78 are released by manipulation of the knurlednuts 82 to release the clamping bars 74 adjacent the members or bearingblocks 68 which support the drum 100'. One of the hand wheels 95 isrotated in a direction whereby the threaded shafts 84, rotated by theworm wheel and worm mechanism 88, 90, move the drum supports or bearingblocks 68 and the roll 100' in a righthand direction, as viewed inFigure 9, to move the projections or fins 17 in a demeshed ornonoverlapping relation.

The bundles of fiber F to be crimped or curled, such as strands,threads, rovings, slivers, yarns, or the like, from the packages orsupply spools G are threaded over the guide member '14 to position thematerial in spaced relation and align the same in a single plane forpassage through the crimping or curling apparatus. Each individualbundle of fiber is threaded into a tube 20 and through a feeding device22 such as that shown in Figures l and 2.

The fiber engaging roll or member 100' is then readjusted by rotation ofone of the hand wheels 95 tomove the projections or fins 17 of theroll-100' into meshing or overlapping relation with the fins orprojections on the roll 100 as shown in Figures 1 and 9. The extent ofoverlapping or enmeshment of the fins or projections 17 is dependentupon the character of crimp or curl desired in the linear material.

The gear drive adjusting mechanism, shown in Figures 9 through 11, isthen adjusted to being the drive gear 162 in proper meshing relationwith the driven gear 128 which rotates the drum 100'. This adjustmentmay be accomplished by releasing the locking nut 175 shown in Figure 9and rotating the hand wheel 174 to move the rod 167 lengthwise, swingingthe triangularly shaped member 130 about the axis of shaft 134 to movethe gear 162 into proper position. The drums 100 and 100' may beindividually and rotatably adjusted relative to the gears 125 and 128 bymanipulating set screws (not shown) carried by the gears and engagingkeys carried by the drum supporting sleeves 112 in order to synchronizethe peripheral spacing of the groups of blades 17 on the respectivedrums.

The motor 150 is energized and, through the reduction gearing containedin the housing, the drive pulley 147 drives the belt 145, rotatingpulley 143, shaft 134, gears 125, 128, 138 and 162, to effectsimultaneous rotation of the drums 100 and 100' in opposite directionsto effect a crimping or curling of the material passing between and incontact with the projections or fins 17. The material feeding devices 22are brought into operation by directing compressed air to each devicethrough a tube 24 whereby each linear bundle of fiber in crimped orcurled form is fed or delivered into an individual container or receiver28..

The drums 100 and 100 are rotated at a speed to eflect a crimping or.curling of the material at a rate of several feet per minute. The rateat which the fiber may be fed through the crimping apparatus isdependent in a measure upon the temperature of the hot roll and theextent of enmeshment or overlap of the vfins or projections 17 to securea crimp or curl of desired character and fixation.

It is to be understood that the rolls or drums equipped with the fiberengaging surfaces or projections may be utilized at various temperaturesand both may heelevated .to a high. temperature if a sharp or acute bendis. desired for successive crimps at opposite sides of the fiber and ifit is desired to have all of the crimps or bends permanently fixed inthefiber.

As previously mentioned, the heat fixation of the crimps or curls at oneside. of the bundle of fiber result in the continuous curled fiberassuming a generally helical shape. The present invention embraces amethod and apparatus for crimping fiber in a manner whereby a threedimensional deformation of crimp or curl'may be pro-4 vided insuccessive groups with a forward and reverse helical or arcuate shape ofthe general character illustrated in Figure 4 providing stress balancedcrimped fiber.

Alternate groups 225 of fibers crimped on one side of the fibers, areseparated by groups 226 (one of which is shown in Figure 4) in which theacute fixed crimp configuration is at the opposite side of the crimpedfiber, the continuous crimped strand or fiber embodying thischaracteristic being generally in the form of a running W with thecrimped regions in a planar formation. An arrangement of fiberengagingmeans and heat controlling means for forming this configuration of fiberor bundles of fiber during crimping or curling operations is illustratedin Figures l6 and 17.

The forward and reverse helical formation of successive groups of crimpsin the fiber are formed by fiber engaging projections or fins on rollswhich are partitioned or divided into sections such as quadrants whereindifferential temperatures exist between opposed sections of the rolls.By this method, heat is alternately applied by the fins or projectionson the rolls to opposite regions or sides of the fiber. As particularlyshown in Figure 16, the fiber crimping rolls 230 and 231 are formed withfins or projections 17 which intermesh in the same manner as the fins 17shown in Figure 9. The rolls or drums 230 and 23l are supported anddriven in the same manner as the drums and 100' hereinbefore described.

Each of the drums 230 and 231 is formed with a cylindrical orsleeve-like portion 234 which accommodates a stream of air for a purposehereinafter explained. Each end of the drum is formed with a wall 236,one of which is shown in Figure 17, the end walls closing the regionwithin the drum exterior of the sleeve portion 234. Each of the drumsmay be formed into sections, such as quadrants, indicated at 238, 239,240. and 241.

The opposed quadrants 239 and 241 of each roll are provided withresistance heating units or shoes 244 for maintaining the projections 17adjacent these quad-rants at a temperature above the softening point ofthe material of the fiber to effect a permanent crimp or deformation toone side of the fiber during its engagement with the hot projections.

Ths sections, regions or quadrants 238 and 240 arranged betweenquadrants 239 and 241 are maintained at a lower temperature viz., atemperature below the softening point of the material of the fiber to becrimped,

so that a permanent deformation is not imparted to the One end 236 ofeach of the drums may be provided I with a pair of current conductingrings or members 248 and 249 which are connected with the heating units244 contained in alternate quadrants or drum sections. Brushes 250 and251 respectively engage the rings for conveying electrical energy to theheating units 244 to heat the opposing quadrants or sections 239 and 241of each roll or drum. If desired a current conductor ring may bedisposed at each end of'a drum for carrying current to the heatingunits, but for purposes of illustration the current conducting ordistributing rings 248, 249 and the cooperating brushes 250 and 251 areillustrated at one end of a drum as shown in Figure 17.

A tube or pipe 254 may be telescoped into the sleeve portion 234 of eachof the drums in the manner shown in Figure 17. The tube 254 forms abearing for one end of the drum 'which is supported in a manner similarto that shown in Figure 9. A fitting or member 256 surrounds 'an endzone of the pipe 254 and is connected As particularly shown in Figure16, the portion of the sleeve 234 adjacent the quadrants 238 and 240 ofeach drum is provided with openings 260 to facilitate flow of air fromthe hollow interior 261 of the cylindrical portion 234 into thenonheated sections of the drums and the air discharged through ventopenings (not shown). The air supplied to pipe 258 flows through thepipe 254 into the chamber 261 and through the orifices or openings 260into the sections or quadrants 238 and 240 for controlling thetemperature of the cool sections. The flow of air into the nonheatedsections or quadrants of each drum may be controlled by valve means (notshown). By regulating the temperature and amount or rate of flow of airor fluid into the chambers 238 and 240, the projections of fins 17'adjacent the nonheated sections or quadrants may be maintained at atemperature below the softening point of the glass or other mineralfiber being crimped by the apparatus.

In certain installations, the walls or partitions between adjacentsections or quadrants may be sufficient to retard heat transfer from theheated sections to the nonheated sections to maintain the pro-pertemperature differential between the adjacent groups of fiber engagingprojections or crimping elements without the use of a temperaturecontrolling fluid.

In the use of the arrangement shown in Figures 16 and 17, successivezones of a continuous bundle of fiber are subjected to groups of heatedfins or projections alternately on opposite sides of the bundle offiber.

The bundle of fiber, moving between the crimping elements, is engaged onone side by heated fins or projections on one drum, forming crimps orcurls in the bundle equal to the number of teeth adjacent a heatedquadrant of the drum. In the succeeding zone, heated projections of theother drum engage the opposite side of the bundle of fiber to impress orimpart crimps or curls to the fiber resulting in a general fiberconfiguration similar to a running W illustrated in Figure 4. Thispattern of crimped fiber provides for a substantially stress balancedproduct and such product does not tend to form a generally helical shapeThe method and apparatus may be utiilzed to advantage in imparting acrimped or curled configuration to a strand or linear bundle of fibershaving a high degree of twist to form a relatively tight; corkscrew-typeof rotational curl A high twist strand, yarn or bundle of fiber fedbetween the crimping elements will effectively be rotated continuouslyunder the influence of the high twist in the strand and, hence a tightrotational curl will be imparted to the twisted strand, yarn or bundleof fiber. A product of this character may be advantageously used where ahigh degree of resiliency or extensibility is desired.

It is to be understood that while electrically energized heating unitsor elements are illustrated for heating the alternate sections orquadrants of the crimping apparatus of Figures 16 and 17, inductionheating or other type of heating suitable for the purpose maybeemployed. The character of the individual or discrete crimps or curlsin the continuous crimped fiber may be modified in their characteristicsby changing or modifying the same factors which control the character ofthe crimp or curl imparted to the fiber by the apparatus hereinbeforedescribed and illustrated in Figures 3 through 15.

The apparatus described involves the use of rotatable fiber engaging anddeforming elements in carrying out the method. The method of fibercrimping or deformation may be accomplished through the utilization offinned belt-like arrangements wherein the fins or fiber engagingprojections are in overlapping or meshing relation. The meshed belt-likearrangements may be maintained at differential temperatures and functionto deform or crimp the fiber in the manner herein described inconnection with the rotatable crimping elements.

The crimped or curled fiber may be processed and spun into threads andyarns for weaving fabrics or such fiber may be processed to formrelatively thin unwoven webs or fabrics especially usable for filters,reinforcement for molded plastic articles, sheet materials and for otherpurposes. The crimped or curled mineral fiber is admirably suited foradmixing or blending with other types and kinds of fibers for both wovenand unwoven textiles or web formations. The glass or mineral fiber maybe combined or blended with vegetable fiber such as cotton, animal fibersuch as wool or hair or synthetic fiber such as acetate rayon, viscoserayon, nylon or other fibers. The admixtures of fiber may be blended inindividual threads or yarns, or threads and yarns of crimped or curledglass fiber may be woven or processed into textiles with individualthreads or yarns of cotton, wool, rayon or other synthetic fiber.

As the crimped glass or mineral fibers are dimensionally stable atnormal temperatures, a mixture of crimped glass fiber with cotton, wool,rayon or other synthetic fiber results in a product having improveddimensional stability, crease resistance, washability, strength andthermal characteristics, and coverage of yarns made from thesecombinations.

It is apparent that, within the scope of the invention, modificationsand different arrangements may be made other than is herein disclosed,and the present disclosure is illustrative merely, the inventioncomprehending all variations thereof.

I claim:

1. The method of deforming mineral fiber including continuouslyadvancing mineral fiber in the direction of its length, heatingsuccessive spaced apant portions of the fiber to a temperaturesufficient to effect a softening of the mineral fiber, heating theremaining portions of the fiber to a different temperature and below thesoften.- ing temperature of the fiber, and forming acute angular crimpsin the fiber at the regions of the high temperature portions of thefiber and rounded crimps in the portions between successive angularcrimps.

2. The method of deforming mineral fiber including continuouslyadvancing mineral fiber in the direction of its length, heatingsuccessive spaced apart portions of the fiber to a temperature ofapproximately 1200 Fahrenheit, heating the remaining portions of thefiber to a temperature of approximately 600 Fahrenheit, and formingacute angular crimps in the fiber at the regions of the high temperatureportions of the fiber and rounded crimps in the portions betweensuccessive angular crimps.

References Cited in the file of this patent UNITED STATES PATENTS1,923183 Blum Aug. 22, 1933 2,002,314 Friedrich May 21, 1935 2,348,182Slayter May 2, 1944 2,394,165 Getaz Feb. 5, 1946 2,647,285 Pfau Aug. 4,1953 2,664,671 Courtney et a1. Ian. 5, 1954 2,668,564 Laros Feb. 9, 19542,669,001 Keen Feb. 16, 1954 2,685,763 Courtney et a1 Aug. 10, 19542,708,813 Bourgeaux May 24, 1955 2,740,992 Shattuck Apr. 10, 19562,751,661 Shattuck June 26, 1956 2,763,898 Sammons et al Sept. 25, 19562,812,569 Lawson et al. Nov. 12, 1957 FOREIGN PATENTS 742,440 GreatBritain Dec. 30, 1955

